Process for producing linear alpha olefins

ABSTRACT

AN IMPROVED PROCESS FOR CATALYTIC POLYMERIZATION, OR OLIGOMERIZATION, OF ETHYLENE TO OBTAIN A REACTION PRODUCT MIXTURE CONSISTING ESSENTIALLY OF C4 TO C200 OLEFINS, INCLUDING ESPECIALLY LINEAR ALPHA OLEFINS. THE OLIGOMERIZATION REACTION IS CONDUCTED BY ADDING ETHYLENE TO A DILUENT AT PRESSURES TO MAINTAIN AN ETHYLENE CONCENTRATION IN THE LIQUID PHASE SUFFICIENT TO SUPPRESS COPOLYMERIZATION REACTIONS INVOLVING THE PRODUCT OLEFINS. IT IS FOUND THAT HIGHER CATALYST ACTIVITY AND STABILITY CAN BE MAINTAINED IF THE TRANSITION METAL HALIDE AND ORGANO ALUMINUM HALIDE CATALYTIC MIXTURE IS MODIFIED, PRIOR TO INITATION OF THE REACTION, WITH A STRONG LWEIS ACID ADDED IN SMALL BUT EFFECTIVE CRITICAL CONCENTRATIONS. MODIFICATION OF THE CATALYTIC MIXTURE ALSO PERMITS OPERATION AT TEMPERATURES RANGING E.G., ABOUT 20 TO 6/ CENTIGRADE DEGREES HIGHER THAN PERMITTED BY USE OF AN UNMODIFIED CATALYST AND HENCE REFRIGERATION NEEDS ARE REDUCED, OR ELIMINATED.

United States Patent 3,655,812 PROCESS FOR PRODUCING LINEAR ALPHA OLEFINS Arthur W. Langer, In, Watchung, N.J., assignor to Esso Research and Engineering Company No Drawing. Filed Mar. 3, 1969, Ser. No. 804,007

Int. Cl. C07c 3/10 U.S. Cl. 260683.15 D 11 Claims ABSTRACT OF THE DISCLOSURE An improved process for catalytic polymerization, or oligomerization, of ethylene to obtain a reaction product mixture consisting essentially of C to C olefins, including especially linear alpha olefins. The oligomerization reaction is conducted by adding ethylene to a diluent at pressures to maintain an ethylene concentration in the liquid phase sufficient to suppress copolymerization reactions involving the product olefins. It is found that higher catalyst activity and stability can be maintained if the transition metal halide and organo aluminum halide catalytic mixture is modified, prior to initiation of the reaction, with a strong Lewis acid added in small but effective critical concentrations. Modification of the catalytic mixture also permits operation at temperatures ranging, e.g., about 20 to 60 centigrade degrees higher than permitted by use of an unmodified catalyst and hence refrigeration needs are reduced, or eliminated.

Traditionally, ethylene is polymerized at selective conditions in the presence of catalytic complexes formed from mixtures consisting of transition metal halides and organo aluminum compounds to yield various products. High molecular weight, high density polymers are formed in the presence of these insoluble Ziegler type catalyst complexes produced, e.g., by reaction of these insoluble Ziegler type catalyst complexes produced, e.g., by reaction between titaniurn tetrachloride and aluminum triethyl. A characteristic of such reactions is that in the formation of the resultant insoluble catalytic complex, the titanium metal is reduced to a metal having a valence of 3 or below.

Oligomers, which have entirely different properties due, in part, to the very limited molecular weight, have also been prepared. The catalyst complexes used for conducting oligomerization reactions are an entirely different complex and the reaction apparently proceeds by a different mechanism. For example, wherein product molecular weight varies inversely with temperature in the reduced titanium catalyst system, it varies directly with temperature in the oligomerization catalyst system. The reactants used in the formation of these oligomerization catalyst complexes include transition metal halides and also organo aluminum halide compounds, added together in specified concentrations, to produce a soluble complex wherein the titanium metal of the complex is unreduced. TiCl, can thus be reacted with AlEt Cl to produce a soluble covalent complex or perhaps an ion pair wherein the titanium metal is unreduced, or has a 4+ valence in accordance with the following formulae:

CI Ol 01 Tioli AlEtzClEt-Ti3r :Al (TiEtClq)+(A1EtCl 010'1 Et Covalent Complex Ion Pair In the formula, Et represents the ethyl group. The 01-]- and a'-- signs represent, respectively, the centers of low and high electron density in the complex. In the ion pair representation, the 0' signs (indicating partial development) are omitted to indicate a more fully developed ionic character.

In forming such oligomerization catalysts, the reactants are premixed in the polymerization diluent at conditions selected to optimize oligomerization catalyst formation, while discouraging formation of the insoluble Ziegler type catalysts. When ethylene is added to a solution of the oligomerization catalytic complex, at appropriate conditions, oligomers, especially Type I or linear alpha olefins, ranging in average molecular weight from about to about 600 are selectivel formed. In fact, linear alpha olefins can be selectively formed in very high concentrations to the virtual exclusion of Type II (RCH=CH1R), Type III (R @CH and Type IV (R C- OHR) olefins.

The present invention is also a process for the production of predominantly C to C olefins, especially linear alpha olefins of number average molecular weight ranging from about 70 to about 600 for the total product. Briefly, this invention relates to polymerizing an ethylene-containing gas in the presence of a catalyst system formed by mixing components comprising a titanium compound, said compound being one selected from the group consisting of TiX TiX OR', TiX O OCR' wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl and an aluminum al'kyl compound such that the ultimate formula of the aluminum alkyl compound is AlR,,X'-,- wherein R is one selected from the group consisting of alkyl, aralkyl and cycloalkyl and X' 'is one selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of ;a diluent at a pressure above 100 p.s.i.g. and a temperature below C. wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction, the improvement therewith consisting of the step of addingto the catalytic mixture at least 10 mole percent, based on the moles of titanium compound present in the catalyst, of a Lewis acid modifier having a metal portion wherein the said metal portion is selected from Groups II, III-A, and V-A of the Periodic Table of the Elements. The Lewis acid is added or otherwise incorporated within the catalytic mixtures in relatively small, critical concentrations, sufficient to alter, to some extent, the character of the soluble complex. The change is manifested by increased activity and stability, Le, a lesser tendency to form the insoluble Ziegler polyethylene catalyst. The catalyst thus not only retains its soluble character but, in fact, any tendency for the production of high molecular weight polymers is further suppressed. Use

of the modified catalyst also permits higher temperature operation to achieve quality results normally achieved at lower temperatures, and hence refrigeration requirements are reduced or eliminated.

Lewis acids, as is known, are those compounds which possess an unfilled orbital that can accept an electron pair from a donor or base, or one which has the capacity of making such orbital available under the influence of a base. Oligomerization catalyst modifiers most useful in the practice of this invention are the strong Lewis acids, particularly those of the metal halide and mixed organo metal halide types; and more particularly those of the Friedel-Crafts catalyst type. The most acidic Lewis acids, where the selected acid is compatible with the system, are the most effective and show the highest degree of activation. The activating strength of the Lewis acids, as metal halides, has been found to correlate quite closely with published relative chloride afiinities for Lewis acids in nonaqueous solutions. (See, e.g., Friedel-Crafts and Related Reactions, volume I, General Aspects. Edited by George A. Olah; Interscience Publishers (1963, Chapter V).) For example, the activity (i.e., activating influence) of aluminum chloride is greaterthan the activity of ferric chloride, the latter has greater activity than stannic chloride, stannic chloride shows greater activity than titanium tetrachloride, the latter shows greater activity than boron trichloride, and the activity of boron trichloride is considerably higher than the activity of silicon tetrachloride. Represented symbolically which is the same order for the chloride ion affinity series.

The modifier is added to the catalytic mixture and the latter treated for a suflicient time, usually from about one to about thirty minutes to eifect the desired modification of the catalyst. Modifiers most useful in the practice of this invention are the metal halides and mixed alkyl metal halides wherein the metal portion is selected from Groups II, III-A, IV, V-A, VI-B, VII-B and VIII of the Periodic Table of the Elements. Exemplary of such metals are beryllium, magnesium, zinc, boron, aluminum, gallium, indium, thallium, tin, lead, titanium, zirconium, hafnium, arsenic, antimony, bismuth, chromium, molybdenum, tungsten, maganese, technetium, rhenium, iron, cobalt, ruthenium, rhodium, palladium, osmium, and the like. Illustrative of metal halides useful as modifiers are zinc chloride, magnesium chloride, boron tribromide, aluminum chloride, gallium tribromide, indium chloride, thallium chloride, .stannous chloride, zirconium tetrabromide, antimony trichloride, antimony pentachloride, bismuth trichloride, ferric chloride, ruthenium tetrachloride, osmium tetrachloride, and the like. Illustrative of suitable alkyl metal halides are ethyl zinc chloride, methyl boron dichloride, ethyl gallium dichloride, methyl indium dichloride, ethyl thallium dichloride, and the like. The utility of diorgano and higher substituted metal halides is marginal, and these must be used with care inasmuch as they can exert a deactivating influence. Exemplary of dialkyl substituted metal halides of some utility are di-n-butyl germanium dichloride, di-isopropyl germanium dibromide, dimethyl tin dichloride, dibutyl tin dibromide, diethyl zirconium dibromide, triethyl antimony dichloride, and the like.

The mode of modifier addition is important, and post addition of the modifier to the catalyst prior to initiation of the oligomerization reaction is preferred because this suppresses or prevents interference in the formation of the catalyst complex and side reactions are suppressed or avoided. The modifiers are added to a reaction mixture or solventcontaining the catalyst in effective concentrations ranging up to about 300 percent, and preferably up to about 100 percent, based on the moles of transition metal halide used in the catalyst preparation. Greater concentrations than necessary to modify the catalyst are undesirable inasmuch as adverse side reactions, e.g., po-

lymerization and isomerization of the product olefins can be produced.

Modifier concentrations as low as 1 mole percent show some effectiveness. Concentrations as low as about 10 mole percent increase the normal catalyst activity as much as three to five-fold. Concentrations of strongly acidic metal halides above about 75 mole percent generally produce some catalyst deactivation at a given polymerization temperature and particularly at temperatures below about 10 C. Concentrations above about mole percent generally produce a very rapid decline in activity.

The polymerization temperature, to some extent, determines the amount of modifiers that can be added without causing deactivation of the catalyst. For example, the deactivation encountered at polymerization temperatures of 10 C. or below as a result of modifier concentrations in the range of 100-800 mole percent can be easily reversed by elevating the polymerization temperature to from about 20 to about 60 C. Surprisingly, activity is regained at elevated temperature without loss in selectivity of the Type I olefin product and without formation of significant amounts of unwanted, high molecular Weight polyethylene. This behavior contrasts quite sharply with that of the unmodified catalyst which yields large amounts of high molecular weight polyethylene at polymerization temperatures above 20 C. These modified catalyst forms, therefore, can be further utilized if the temperature of the reaction system is elevated beyond that at which deactivation is produced. Inasmuch as the activity, yield, and product quality are approximately the same as exhibited at the lower polymerization temperature, a clear process advantage is gained in that refrigeration requirements are reduced. In general, it has been found most preferable for purposes of activating and stabilizing the catalyst to employ from about 10 to about 35 mole percent of the modifier, especially the more active modifiers, when the polymerization is conducted in polar diluents at temperatures below 10 C.; and from about 50 to about mole percent for operations in nonpolar diluents or at temperatures in the range of from about 20 to about 60 C.

The mechanism of the modification is not fully understood, but it is apparent that the addition of the modifier increases the ionic character of the catalyst. It is believed to increase the stability of the ionic form which is most responsible, or perhaps entirely responsible, for formation of oligomers. While applicants do not Wish to be bound by any specific theory, it is believed that the added modifier promotes formation of the ionic catalyst and enhances the ionic (acidic) character of the catalyst. Greater anion solvation (probably through complex anion formation) and modification of the original catalyst, supra, occurs to produce said effects as represented by the following equation:

EtTiCla AlEtClz ('liEtOM)(AlEtClfl-(MXOn In the formula, MX represents a Lewis acid modifier of the metal halide type, M specifically representing a metal and X halogen. The letter n represents the number of moles of modifier employed.

Whatever the mechanism, however, there is a definite response of the original catalyst to the modifier addition, or treatment, and stability of the catalyst and catalyst activity is increased.

An outstanding advantage of this discovery is that the temperature of the reaction system can be elevated from about 20 to about 60 centigrade degrees to attain oligo mers of the same average molecular weight range as formerly attained at the lower temperatures without modifier addition. Heretofore, optimum conditions generally favored conducting the reaction at about 0 C. to 10 C., this necessitating high refrigeration requirements. In accordance with the present process, however, the reaction can be conducted at temperatures up to about 75 C. with ordinary cooling water to achieve similar results.

The unmodified catalyst employed in the reaction system is a complex reaction pro-duct which is substantially soluble in the polymerization system. The complex is obtained by partially reacting a reducible, heavy transition metal halide, the metallic portion of which is selected from Groups IV-B, VI-B, and VIII, of the Periodic Chart of the Elements, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X wherein n is less than 2, and preferably less than 1; R is alkyl, cycloalkyl or aralkyl, preferably containing from 1 to about 20 carbon atoms, for example, methyl, ethyl, isobutyl, cyclohexyl, benzyl, etc.; and X is chlorine, bromine or iodine. The preferred transition metal used in forming the complex is a titanium compound having a valency of 4, as represented by the formula: TiX A wherein a=3 or 4, b= or 1, and a+b=4, X=chlorine or bromine, and A is chlorine, bromine or an anion derived from a protonic compound such as an alcohol (R'OH) or a carboxylic acid (R COOH). The R of the protonic compound can be an alkyl, aryl, aralkyl or cycloalkyl group. The TiX A component can be made in situ by reacting TiX with the protonic compound. Thus, the preferred transition metal component of this invention may be selected from the groups TiX TiX OR' and TiX OOCR. Typical examples of such compounds are TiCl TiBr TiX OC H; an-d TiX OOCH The aluminum alkyl halide component, usually a mixture, is prepared from aluminum alkyl halides of the general formulas RR'AlX and R"A1X wherein R, R and R" are similar or dissimilar, and thus represent hydrocarbon radicals such as alkyl, cycloalkyl or aralkyl containing, preferably, from 1 to about 20 carbon atoms, and X is a halogen such as chlorine, bromine or iodine.

The molar ratio of alkyl aluminum halides in the mixture and the overall molar ratio of the alkyl aluminum halides to the transition metal halide in the unmodified complex is not critical to this invention as long as the AlR,,X reaction product has the proper formula. The molar ratio of AlR X to TiCl can be 0.1/1 to 150/1 or more. Catalyst concentration is normally in the range of 0.1 to 10 grams per liter of diluent.

Ethylene is unique in the instant invention in that other olefins do not respond to give linear alpha olefins. Therefore, it is desirable to use essentially pure ethylene or mixture of ethylene with inert gases as the feed for the process of this invention. Ethylene feeds containing minor amounts of other olefins can be used but it must be realized that the copolymerization will, to some extent, decreased product linearity.

The polymerization diluent is a very important feature of this invention insofar as it affects catalyst activity and product molecular Weight. Aromatic, halogenated aromatic, aliphatic and naphthenic diluents can all be used satisfactorily. In general, activity decreases and molecular weight increases with decreasing diluent polarity. Thus, the use of modified catalysts, which tend to decrease molecular weight and to boost activity, permits the used of less expensive nonpolar solvents to achieve the same results obtained With polar diluents. Moreover, even liquid ethylene can be used as a solvent. This offers the advantage, in commercial processes, of eliminating the need for solvent recovery systems.

Preferred diluents from a cost effectiveness standpoint are the readily available aliphatic and naphthenic compounds such as butane, isobutane, pentanes, hexanes, heptanes, cyclopentane, methylcyclopentane, cycle-hexane and the like. Simple aromatics such as benzene, toluene and xylene are also ideal diluents, with the exception that they can yield olefin alkylation products in the presence of acidic metal halide modifiers, particularly when trace 0 or H O contaminates are present. Halogenated aromatics are excellent diluents but are expensive relative to the aliphatic and naphthenic diluents. Less preferred solvents are halogenated aliphatic compounds which,

though capable of being employed in the process of preparing linear alpha olefins, require the utilization of higher pressures to achieve average molecular weights of the same order as the preferred solvents. The less desirable halogenated aliphatic diluents include methyl chloride, ethyl chloride, dichloromethane, and the like. Mixed diluents can be used. For example, mixtures of aliphatic or naphthenic diluents with aromatics or haloaromatics can be readily used. The diluent or diluent mixture can be used to some extent to control the product molecular weight distribution to obtain maximum selectivity to the desired olefin products.

The oligomerization reaction must be conducted at sufficient pressure to avoid the formation of highly branched olefins and to obtain linear olefins in high selectivities. Although some variations in pressure are permitted, depending upon the catalyst composition, diluent and temperature, the pressure should be maintained above about 100 p.s.i.g. in order to produce commercially attractive yields (at least above 5 weight percent and preferably above 10 weight percent olefins in the reactor efiluent) of linear alpha olefins having a purity greater than about percent. Pressures can range as high as 1000 p.s.i.g., and higher, but at very high ethylene pressures the process may become uneconomical because of the equipment requirements and ethylene recycle. Preferably, the pressure ranges from about 200 p.s.i.g. to about 900 p.s.i.g. of ethylene pressure.

The ratio of moles of ethylene to the moles of product must be above about 0.8 in order to effect the selective synthesis of ethylene to linear olefins. The preferred molar ratio of ethylene to products is above about 5. The upper limit of the mole ratio of ethylene to product must be above 0.8 or the product formed contains more than 10 percent branched chain olefins at product concentrations required to obtain commercially attractive yields.

The process of this invention is carried out at selected conditions of temperature and pressure which will maintain ethylene in the proper mole ratio with the product olefins. Temperature selection permits control of the average molecular weight of the product. Preferably, the reaction can be carried out at temperatures below about C., but more preferably it is carried out at between about 0 C. and about l+50 C.

Reaction times are not particularly critical when operating under the preferred conditions and they will normally be in the range of 0.1 to 5 hours toobtain product concentrations greater than 5 percent by Weight in the diluent. The process can be carried out in batch or continuous operation. However, high product purity and high concentration are achieved most easily in batch reactions or in continuous systems operating under essentially plug how.

The oligomerization reaction is not generally carried to completion, but quenched to terminate the reaction at an optimum desired time. After the catalyst has been effectively quenched, e.g., by adding isopropyl alcohol, the residues can be removed from the products in any conventional way, such as washing with water or aqueous caustic, adsorption, ion exchange resins, and the like.

The following demonstration, and illustrative examples, bring out the more salient features of the invention.

EXAMPLES The following demonstration is illustrative of the experimental procedure used in carrying out ethylene oligomerization without use of a modifier.

Catalyst preparation Approximately 400 grams of xylene (percolated over alumina and stored over sodium ribbon) was charged to a dry 500 ml. flask equipped with a small side arm, a serum cap, and an adapter to permit charging to an autoclave.

Forty-four hundredths ml. of TiCl (4 millimoles) were injected into the xylene solvent.

The flask containing the TiCl -xylene solution was then wrapped in aluminum foil, and the contents cooled to 15 C. by immersion of the flask into a stirred ice-water bath. Then 3.4 ml. of a 20 percent aluminum alkyl mixture in xylene (4 millimoles of aluminum ethyl dichloride and 2 millimoles of aluminum diethyl chloride) were injected into the TiCl -xylene solution. The resulting solution was treated by stirring for 30 minutes at 15 C.i1 C. The flask was then removed from the ice-water bath, weighed and the contents thereof pressured into a 2-liter Parr autoclave. Weighing the catalyst flask after charging permitted an accurate determination of the weight of catalyst solution charged to the autoclave. Four hundred and nineteen grams of the catalyst, clear and red-orange in color, was charged to the autoclave.

Oligomerization The oligomerization reaction was carried out in a 2- liter Parr autoclave. The contents of the autoclave were precooled to 25 C. prior to charging the catalyst solution. After the catalyst was added, ethylene (dry and oxygen-free) was pressured into the autoclave. The temperature rose quite rapidly to around C. and was maintained at +2 C. for one hour. The pressure in the autoclave was maintained at 500 pounds by adding ethylene as needed.

The run was terminated by pressuring in 14.4 grams of isopropanol while the reactor was still under reaction conditions (+2 C., 500 p.s.i.g. ethylene pressure). The quenched product was stirred for approximately 5 minutes and the unreacted ethylene vented off. After all the ethylene had been vented, the autoclave was weighed prior to dissassembly to obtain a yield figure. The autoclave was then disassembled and the total product removed. A sample of product was analyzed on a G.C. column to obtain a yield figure and product distribution data. The yield of liquid olefins was 176 grams. The olefin concentration in the reaction mixture was found to be 32.8%..

Product workup- The alcohol quenched product was water-washed using two 500 ml. portions of deionized water. After separating off the water, the amount of higher molecular weight polyethylene was determined by filtration, air drying and finally drying for 1 hour in a vacuum oven at 125 C. and 26" Hg vacuum. The yield of high molecular weight polyethylene was found to be 1.4 grams or 0.7 percent, based on the weight of olefins. (Polyethylene using unmodified catalyst, under generally similar conditions, has been found to vary as high as 2.0 weight percent, or more). The filtered liquid product (xylene plus ethylene oligo mers) was dried and analyzed using capillary G.C. techniques. Product linearity (weight percent linear alpha olefins in C C fraction) was found to be 97.4. The average molecular weight (Mn) of the olefins was determined as 118.

Catalyst modification An additional series of runs was made wherein the catalyst was treated and modified by post addition of a metal halide or alkyl metal halide to the catalyst prior to conducting the oligomerization reaction. Thus, the catalyst preparation procedure described above was repeated except that at the end of the thirty minute treating period following addition of the aluminum alkyl mixture in xylene to the TiCl -xylene solution, a suflicient amount of the modifier was added to provide 25 mole percent, based on the TiCl, employed. Oligomerization reactions were then initiated.

The results of all of these runs in terms of activity (grams olefins per gram of TiCL; reacted per hour) and product quality are as summarized in Table I below:

TABLE I Standard catalyst, 2TiCl AlEtzCl, ZAIEtClz Catalyst concentration, 0.02 M (excluding modifier) Metal halide modifier, 25 mole percent on T1014. Added after pretreat Polymerization, 2 C., 500 p.s.i.g. ethylene Product quality Olefin Activity, c0110., wt. Average Type I Metal g. olefin/ percent in molecular olefin, Example halide g. TiCl4/ product wt. of CiTCfl) out, Number modifier hr. mixture product wt. percent From the foregoing data it will be observed that the most acidic halides produce the greatest amount of activation. Olefin product quality, in general, remains very high, and often is improved despite the increased activity.

Activity is not the sole factor in the selection of a modifier, as illustrated, e.g., by reference to Example 3. It is generally desirable to select the most active metal halides for catalyst modification, but it is essential to do so in consideration of the totality of conditions imposed on the system. For example, in the above data it is shown that stannic chloride, a powerful modifier, adversely affects the quantity of Type I olefin produced. This, however, need not be so in all reaction systems or at all conditions. The reason for the deterioration in Type I olefin production is because this particular activator is incompatible with the system at the conditions chosen. Alkylation of the xylene solvent competes with the basic reaction thus lowering product quality.

One method of controlling modifier activity is by the use of substituent groups to form organo metal halides, particularly the alkyl substituted metal halides and more particularly the mono alkyl substituted metal halides. These are useful modifiers in the practice of this invention. Substitution of the halide substituents of the metal halides is desirable, generally, where the aim is to decrease the activity of a particular metal halide species, because substitution decreases the acidity. In certain instances, however, substitution also suppresses side reactions, particularly alkylation of the solvent. Over-substitution, however, can in certain instances convert all or some portion of the catalyst into the conventional Ziegler form and hence increase the yield of high molecular weight polyethylene. Alkyl substituents, particularly in limited number, produce such tendency to a lesser extent than aryl substituents. The alkyl, and particularly the mono alkyl substituted metal halides, is satisfactory because there is little or no tendency to promote formation of the conventional Ziegler-type catalysts and hence to produce the undesired high molecular weight polyethylene.

The following selected data, obtained under the conditions defined for Examples 1 through 6, are illustrative of the use of organo substituted organo metal halides. In Table 11 below, the activity and average molecular weight of the product obtained by use of various alkylated tin halides is described, a derivative of tin having been selected in view of an adverse effect caused by stannic chloride in the above examples.

TABLE I1 Catalyst base, 2TiCl4, AlEtzCl, 2A1EtClg Catalyst conc., 0.02 M in xylene (excluding additive) Additive conc., 25 mole percent on TiClr. Added after pretreat Polymerization, 2 0., 500 p.s.i.g. CzH4 elevated temperatures, is absent in the activated catalyst runs.

Product quality Olefin conc., wt. Type 1 Oregano ctivlty, percent Average olefin, substituted olefin in molecular -0 metal halide g. TiCl4/ product wt. of cut,wt Example Number modifier hr mixture product percent None 220 28. 4 118 97. 0 7 SIl(C4Hn) 013.... 550 50.0 108 96. 4 8 Sn(CzH)2C1z- 330 37. 4 117 98. 5

It is thus seen that activity and product quality can be controlled by organo substitution of the metal halide modifier.

The following selected data, given in Table III below,

demonstrate low temperature deactivation and subsequent K TABLE IV.EFFECT OF ACTIVATORS ON INSOLUBLE POLYMER YIELDS Wt. percent high Mole Polymer molecular Weight Example percent temp., polyethylene on Number Modifier on TiCli C. total product;

It is therefore apparent that the activators effectively stabilize the catalyst against conversion to conventional Ziegler catalyst forms.

The following selected comparative data, Table V, show the results obtained when conducting oligomerization reactions in nonpolar solvents, even ethylene itself.

TABLE V Basic catalyst composition (millimoles), 4TiCl4, 4AlEtCl 2AlE t Cl Temperature, 02 C.

Pressure, 500-550 p.s.i.g.

Time, 60-90 minutes Polyethylene, wt. Type I Activity, g. percent on Average olefin, Example Metal halide ohgomer/g. total molecular 012-621) cut, Number Diluent modifier TiOli/hr. product weight wt. percent Heptane. None 3. 5 300 11 do 8 mmole T1014. 68. 0 0. 0 150 12 Ethylene 1 d0 175 17. 0 120 94. 5 Xylene None 170 118 96.0 13 Heptane 4 mmole 811014--" 27. 0 0. 0 96 14 do 1,5 mmole AlBn. 80.0 0.0 141 96 1 Under run conditions, the diluent composition was approximately 96% liquid ethylene, 4% xylene (by 2 Under run conditions, the approximate diluent composition was liquid ethylene, 40% xylene (by Weight).

weight).

TABLE III [Catalyst containing 150 mole percent AlBr; on T1014] Average Activity, Type I molecular Example Run temp, g. olefin/g. ole weight of Number C. TiCh/hr. (Cu-C20) product As observed, activity increases rapidly with increasing temperature, product Type I olefin content decreases only slightly with increasing temperature and the average molecular weight of the product remains fairly constant.

The following selected data, given in Table IV below, shows that metal halide modifiers improve catalyst stability. As shown, high molecular weight polyethylene obtained with the unmodified catalyst, particularly at It is thus shown that the modified catalysts function well in nonpolar diluents, parafiins and even ethylene. This is surprising because the unmodified catalyst is relatively inactive.

Specifically, it was found that ethylene oligomerization could be conducted in a diluent comprised of approximately percent liquid ethylene, a nonpolar hydrocarbon. The remaining 5 percent of the diluent was xylene and could have been other suitable solvents used for premixing of catalyst components. The catalyst, prepared by reacting TiCl and a mixture of aluminum alkyl halides so that the ultimate alkyl formula is AlR,,X (wherein n is 2 and preferably 1), has been shown to give high molecular weight polyethylene or at best low yields of high average molecular weight oligomers when used in nonpolar diluents.

Surprisingly, also, it was found that catalyst activity and the oligomer product obtained in a predominantly 1 1 liquid ethylene diluent was comparable to that obtained normally in a predominantly xylene diluent.

The Type I olefin content of the sample prepared in liquid ethylene was lower by only 1.5 weight percent than the sample prepared in xylene. A lower conversion level and a reduction in the excess TiCl can improve the Type II olefin content.

An incentive for use of an ethylene diluent process is that it would eliminate much of the on-site investment required for distillation and recovery of other solvents. Further, the use of liquid ethylene is advantageous in use of a boiling (auto-refrigerated) reactor.

It is readily apparent that various changes and modifications can be made without departing from the spirit and scope of the present invention.

Having described the invention, what is claimed is:

'1. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the Group consisting of TiX TiX OR', TiX OOCR' wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X' wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction'product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least mole percent, based upon the moles of titanium metal halide present in the catalyst system, of either metal halides or mixed alkyl metal halides having a metal portion selected from Group II, of the Periodic Table of Elements whereby the activity and stability of the catalyst system is greatly enhanced.

2. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed 'by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR, TiX OOCR wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X' wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system, of metal halides having a metal portion selected from Group III-A of the Periodic Table of Elements whereby the activity and stability of the catalyst system is greatly enhanced.

3. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR', TiX 0OCR' wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR,,X' wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system, of mixed alkyl metal halides wherein the metal portion is boron.

4. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR', TiX OOCR' wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR XQ wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system, of mixed alkyl metal halides wherein the metal portion is gallium.

5. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR', TiX OOCR' wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X' wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X' is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is .greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole 13 percent, based upon the moles of titanium metal halide present in the catalyst system, of mixed alkyl metal halides wherein the metal portion is indium.

6. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR, TiXgOOCR wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AIR,,,X wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least mole percent, based upon the moles of titanium metal halide present in the catalyst system, of mixed alkyl metal halides wherein the metal portion is thallium.

7. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR, TiX OOCR wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system of either metal halides or mixed alkyl metal halides wherein said metal portion is tin, whereby the activity and stability of the catalyst system is greatly enhanced.

8. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR, TiX OOCR wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein themole ratio of ethylene to the reaction product is maintained above 0.8

throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system, of either metal halides or mixed alkyl metal halides having a metal portion selected from Group V-A of the Peniodic Table of Elements whereby the activity and stability of the catalyst system is greatly enhanced.

9. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiXgOR TiX OOCR wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR,,X wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system of either metal halides or mixed alkyl metal halides wherein said metal portion is silicon, whereby the activity and stability of the catalyst system is greatly enhanced.

10. In a process for preparing a product of linear alpha olefins of number average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR', TiX OOCR' wherein X is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X wherein R is selected from the group consisting of alkyl, aralkyl and cycloalkyl, X is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the step of adding to the catalytic system at least 10 mole percent, based upon the moles of titanium metal halide present in the catalyst system of either metal halides or mixed alkyl metal halides wherein said metal portion is germanium, whereby the activity and stability of the catalyst system is greatly enhanced.

11. In a process for preparing a product of linear alpha olefins of number of average molecular weight ranging from about 70 to about 600 wherein an ethylene containing gas is polymerized in the presence of a catalyst system formed by mixing components comprising a titanium compound selected from the group consisting of TiX TiX OR, TiX OOCR wherein X is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AlR X' wherein R is selected from the group consisting of chlorine and bromine and R is selected from the group consisting of alkyl, aryl, aralkyl and cycloalkyl, with an aluminum alkyl halide compound such that the ultimate formula of the aluminum alkyl compound is AIR ,X wherein R is selected from the group consisting of alkyl, aralkyl and cycloalky'l, X' is selected from the group consisting of chlorine, bromine and iodine and n is less than 2, in the presence of a diluent at an ethylene pressure above 100 p.s.i.g. and at a temperature below 75 C., wherein the mole ratio of ethylene to the reaction product is maintained above 0.8 throughout the reaction and a reaction product having at least 90 mole percent linear olefins is recovered in which the product olefin concentration is greater than 5 weight percent based on the diluent and reaction product, further including the References Cited UNITED STATES PATENTS 3,441,630 4/1969 Langer et a1. 260-683.15 3,472,910 10/1969 Favis 260-683.15

PAUL M. COUGHLAN, JR.. Primary Examiner US. Cl. X.R.

252-429 C; 260-94.9 E, 671 C 

